Ultra-precise CNC machining, additive manufacturing and joining technology for the high-tech industry in Birkenfeld.
Kappler GmbH & Co. KG
BirkenfeldNew on Amplifa
Company
Kappler CNC manufactures ultra-precise components, assemblies and fixtures for the semiconductor industry (EUV and DUV technologies), the optical industry, aerospace, energy and infrastructure, medical technology, and general mechanical engineering. The service portfolio includes 5-axis milling (components up to 12,000 x 4,200 x 2,000 mm), turn-mill machining, Swiss-type turning, grinding, ultra-precision machining with 4 µm positioning accuracy, ultrasonic machining of glass, ceramics and hard metals, EDM, selective laser melting (SLM) as well as joining processes such as friction stir welding, TIG, MIG/MAG, laser and electron beam welding, diffusion welding and brazing/soldering. Additional services include surface treatment, heat treatment and holistic project management including technology development and process qualification. More than 200 employees produce at a 36,500 m², climate-controlled, vibration-damped and automated site in Birkenfeld with more than 140 CNC machines. Quality assurance is carried out, among other things, with Zeiss coordinate measuring machines for large components up to 8,000 mm measuring length.
- Site
- Birkenfeld
- Processes
- CNC milling technology (5-axis, automation), CNC turning technology (turn-mill centers, Swiss-type turning), Grinding technology, Additive manufacturing (SLM, LASERTEC 30 SLM), Ultrasonic/HSC machining, CNC EDM (wire and sinker EDM), Friction stir welding, TIG, MIG/MAG and laser welding
- Materials
- Glass, Ceramics, Hard metals
- Certificates
- ISO 9001, DIN EN ISO 14001, Measuring process assessment (MPA) by Carl Zeiss IMT
- Founded
- 1934
- Employees
- >200
- Industries
- Semiconductor industry (EUV/DUV), Optical industry, Aerospace, Energy and infrastructure, Medical technology, Mechanical engineering
- 01
Project management & feasibility analysis
- 02
CNC milling (5-axis)
- 03
CNC turning / Swiss-type turning
- 04
Grinding
- 05
Ultrasonic/HSC machining
- 06
EDM
- 07
Additive manufacturing (SLM)
- 08
Joining (welding, brazing/soldering)
- 09
Surface treatment
- 10
Heat treatment (annealing, ageing)
- 11
Quality assurance / metrology
- 12
Assembly
Locations
Birkenfeld
DEProduction site (36,500 m²), climate-controlled and automated manufacturing
- Part weight / size
- Milled parts up to 12,000 x 4,200 x 2,000 mm
- Lot size
- n/a
- Materials
- Metals, glass, ceramics, hard metals
- 5-axis machining centers
- 3x Hermle C42 robot cell
- DMG 340 µ-precision
- DMG 210 µ-precision
- DMG CTX beta TC
- DMG CTX gamma TC
- DMG NTX 3000 with robot
- Traub TNL Swiss-type lathe
- Vertical grinding machine with pallet changer
- DMG LASERTEC 30 SLM
- 2x Sauer ultrasonic 5-axis
- Zeiss MMZ-M CMM
- Zeiss MMZ-G CMM
- ZeroClamp / DMG Robo2Go / PH cell / Hermle HS flex
Components
Inside the production
Industries
15 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis machining centers (with rotary tables) | – | 1 | max. component 12,000 x 4,200 x 2,000 mm | – | Birkenfeld |
| Robot cell with linear robot | Hermle C42 | 3 | – | – | Birkenfeld |
| Ultra-precision machining centers µ-precision | DMG MORI DMG 340 µ-precision | 1 | – | – | Birkenfeld |
| Ultra-precision machining centers µ-precision | DMG MORI DMG 210 µ-precision | 1 | – | – | Birkenfeld |
| Turn-mill center with 5-axis simultaneous machining | DMG MORI CTX beta TC | 1 | – | – | Birkenfeld |
| Turn-mill center with 5-axis simultaneous machining | DMG MORI CTX gamma TC | 1 | – | – | Birkenfeld |
| Turn-mill center with robot | DMG MORI NTX 3000 | 1 | – | – | Birkenfeld |
| Swiss-type lathe | Traub TNL | 1 | Machining up to Ø 40 mm | – | Birkenfeld |
| Vertical grinding machine with pallet changer | – | 1 | max. 2000 x 1000 x 1000 mm | – | Birkenfeld |
| SLM system (quad laser, 600 W each) | DMG MORI LASERTEC 30 SLM 3rd generation | 1 | 325 x 325 x 400 mm, layer thickness from 30 µm | – | Birkenfeld |
| Ultrasonic machines (5-axis) | Sauer | 2 | – | – | Birkenfeld |
| Coordinate measuring machine for large components | Zeiss MMZ-M | 1 | 3000 x 6000 x 2000 mm | – | Birkenfeld |
| Coordinate measuring machine for large components | Zeiss MMZ-G | 1 | 4000 x 8000 x 3000 mm | – | Birkenfeld |
| Coordinate measuring machines | Zeiss | 2 | – | – | Birkenfeld |
| Pallet changer magazines / automation (ZeroClamp, DMG Robo2Go, PH cell, Hermle HS flex) | – | 1 | – | – | Birkenfeld |
Additional services
Reference customers
Quality
Quality assurance is performed with Zeiss coordinate measuring machines (up to 4,000 x 8,000 x 3,000 mm for large components), 3D scanners, digital microscopes, helium leak testing down to <1x10-11 mbar*l/s, and pressure and stress testing up to 15 bar in vibration-damped, climate-controlled and cleanroom-filtered measuring rooms. In addition, hardness, magnetism, conductivity and volume flow tests are used, as well as ultrasonic, CT and metallographic inspections via partners.
| Evidence | Birkenfeld |
|---|---|
| ISO 9001 | |
| DIN EN ISO 14001 | |
| Measuring process assessment (MPA) by Carl Zeiss IMT |
History
- 1934
Friedrich Kappler registers the company in Gräfenhausen-Birkenfeld; self-employment begins with a press machine in the cellar.
- 1938
Relocation to Karlsruher Straße in Gräfenhausen; customers include Marwitz und Hauser, Stuttgart.
- 1950-1960er
Reconstruction, manufacture of bench drilling machines; deliveries to Salamander (fixtures, stamping dies, tools).
- 1967
After the accidental death of Friedrich Kappler (1965), his daughter Hildegard Gottschling and her husband Willy Gottschling take over the company.
- 1970/71
Conversion into a production hall; later construction of machines for jewellery chain manufacturing (up to 480/year) and eyewear parts.